WO2013021162A1

WO2013021162A1 - High-g inertial igniter

Info

Publication number: WO2013021162A1
Application number: PCT/GB2012/050590
Authority: WO
Inventors: Jahangir S. Rastegar; Thomas Spinelli
Original assignee: Omnitek Partners Llc
Priority date: 2011-08-10
Filing date: 2012-03-16
Publication date: 2013-02-14
Also published as: US20120205225A1; US8875631B2; EP2742293A1; EP2742293B1

Abstract

A method for igniting a thermal battery upon a predetermined acceleration event. The method including: rotatably connecting a striker mass to a base; aligning a first projection on the striker mass with a second projection on the base such that when the striker mass is rotated towards the base, the first projection impacts the second projection; and preventing impact of the first and second projections unless the predetermined acceleration event is experienced.

Description

HIGH-G I ERTIAL IGNITER

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a cont uatlon-in-part of U.S. Application Serial Number 12/955,8^6 filed on November 29. 2010. the entire contents of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

ί .. Field of the invention

Tbe present disclosure relates generally to mechanical igniters, and more particularly to compact, reliable and easy to manufacture mechanical igniters for thermal batteries and the like that are activated by higli-G shocks such as by the gun firing setback acceleration.

2, Prior Art

Thermal batteries represent a class of reserve batteries that operate at high temperature, Unlike liquid reserve batteries, in thermal batteries the electrolyte is already in the cells and therefore does not require a distribution mechanism such as spinning. The electrolyte is dry, solid and non-conductive, thereby leaving the battery in a non-operational and inert condition. These batteries Incorporate pyrotechnic heat sources to melt the electrolyte just prior to use hi order to make tbem electrically conductive and thereby making the battery active. The most common internal pyrotechnic is a blend of Fe and KCIO₄. Thermal batteries utilise a molten salt to serve as the electrolyte upon activation. The electrolytes are usually mixtures of alkali-halide salts and are used with the Li(Si)/FeS₂ or Li(Si)/CoS₂ couples. Some batteries also employ anodes of Li(Al) In place of the Li(Si) anodes. Insulation and internal heat sinks are used to maintain the electrolyte in Its molten and conductive condition during the time of use. Reserve batteries are Inactive and inert when manufactured and become active and begin to produce power only when they are activated.

Thermal batteries have long been used in munitions and other similar applications to provide a relatively large amount of power during a relatively short period of time, mainly during the munitions flight. Thermal batteries have high power density and can provide a large amount of power as long as the electrolyte of the thermal battery stays liquid, thereb

conducti ve. The process of manufacturing thermal batteries is MgMy labor intensive and requires relatively expensive facilities. Fabrication usually involves costly batch processes, including pressing electrodes and electrolytes into rigid wafers, and assembling batteries by hand. The batteries are encased in a hermetically-sealed metal container that is usually cylindrical in shape. Thermal batteries, however, have the advantage of very long shelf life of u to 20 years that is required for munitions applications.

Thermal batteries generally use some type of igniter to provide a controlled pyrotechnic reaction to produce output gas, flame or hot particles to ignite the heating elements of the thermal battery. There are currently two distinct classes of igniters that are available for use in thermal batteries. The first class of igniter operates based on electrical energy. Such electrical igniters, however, require electrical energy, thereby requiring an onboard battery or other power sources with related shelf life and/or complexity and volume requirements to operate and initiate the thermal battery. The second class of igniters, commonly called "inertial igniters⁵⁵, operates based on the firing acceleration, The inertial igniters do not require onboard batteries for their operation and are thereby often used in bigh-G munitions applications such as in gun-fired munitions and mortars.

in general, the inertial igniters, particularly those that are designed to operate at relatively low impact levels, have to be pro vided with the means for distinguishing events such as accidental drops or explosions in their vicinity from the firing acceleration levels above which they are designed to be activated. This means thai safety in terms of prevention of accidental ignition is one of the main concerns in inertial igniters.

In recent years, new improved chemistries and mannfacnming processes have been developed thai promise the development of lower cost and higher performance thermal batteries that could he produced in various shapes and sizes, including their small and miniaturized versions. However, the existing inertial igniters are relatively large and not suitahle for small and low power thermal batteries, particularly those that are being developed for nse in miniaturized fuzing, future smart munitions, and other similar applications. This is particularly the case for thermal batteries used in gun-fired munitions that are subjected to Mgh G

accelerations, sometimes 10,000-30,000 G and higher.

The need to differentiate accidental and initiation accelerations by the resulting impulse level of the event necessitates the employment of a safety system which is capable of allowing initiation of the igniter only dining Mgh total impulse levels. The safety mechanism can be thought of as a mechanical delay mechanism, after winch a separate initiation system is actuated or released to provide ignition of the pyrotechnics, An inertial igniter that combines such a safety system with an impact based initiation system arid its alternative embodiments are described herein together with alternative methods of initiation pyrotechnics.

Inertia-based igniters must therefore comprise two components so that together they provide the aforementioned mechanical safety (delay mechanism) and to provide the required striking action to achieve ignition of the pyrotechnic elements. The function of the safety system is to fix the striker in position until a specified acceleration time profile actuates the safety system and releases the striker, allowing it to accelerate toward its target under the in fluence of the remaining portion of the specified, acceleration time profile. The ignition itself may take place as a result of striker impact, or simply contact or proximity. For example, the striker may be akin to a firing pin and the target akin to a standard percussion cap primer, Alternately, the striker-target pair may bring together one or more chemical compounds whose combination with or without impact will, set off a reaction resulting in the desired ignition.

A schematic of a cross-section of a conventional thermal battery and inertial igniter assembly is shown i Figure 1. In thermal battery applications, the inertial igniter 10 (as assembled in a housing) i generally positioned above (in the direction of the acceleration) the thermal battery housing 1.1. as shown in Figure 1.. Upon ignition, the igniter initiates the thermal, battery pyrotechnics positioned inside the thermal battery through a provided access 12. The total volume that the thermal battery assembly 16 occupies within munitions is determined by the diameter 17 of the thermal battery housing 11 (assumiug it is cylindrical) and the total height 15 of the thermal battery assembly 16, The height 14 of the thermal battery for a gi ven battery diameter 17 is generally determined by the amount of energy that it has to produce over the required period of time. For a given thermal batter height 14, the height 13 of the inertia! igniter 10 would therefore determine the total height 15 of the thermal battery assembly 16, To reduce the total space that the thermal battery assembly 16 occupies within a munitions housing (usually determined by the total height 15 of the thermal battery), it is therefore important to reduce the height of the inertial igniter 10. This is particularly important for small thermal batteries since in such eases and with currently available inertial igniter, the height of the inertial igniter portion 13 is a significant portion of the thermal batter height 15.

It is, therefore, highly desirable to develop inertial igniters that are smaller in height and also preferably in volume for thermal batteries in general and for small thermal batteries in particular . This is particularly the case for inertia igniters for gun-fired munitions that experience high G firing setback accelerations levels, e.g., setback acceleration levels of 10· 30,000 Gs or even higher, since such thermal batteries would have significantly higher no~fire and all -fire acceleration requirements, which should allow the development of inertial ig iters that are smaller in height and possibly even in volume.

Accordingly, an inertia! igniter for igniting a thermal battery upon a predetermined acceleration event is provided. The inertia! igniter comprising: a base having a first projection: a stiiker mass rotatably connected to the base through a ro able connection, the base having a second projection aligned with the first projection such that when the striker mass is rotated towards the base, the first projection impacts the second projection; and a rotation prevention mechanism for preventing impact of the first and second projections unless the predetermined acceleration event is experienced.

The rotation prevention mechanism can. comprise a restriction member for restricting rotation of the sticker mass, the restriction member being disposed directly or indirectly between the striker mass and the base. The restriction, member can have a weakened portion, which fails upon, the predetermined acceleration event thereby allowing the striker mass to rotate towards the base. The inertia! igniter can .further comprise a spring for biasing the striker mass in. a biasing direction away from, the base. The inertia! igniter can further comprise a stop for limi ting the movement of the striker mass in the biasing direction. The restriction member can be arranged in shear and the weakened portion ca be a reduced cross-sectional portion. The restriction, member can be arranged in tension and the weakened portion can be a reduced cross-sectional portion.

The rotation prevention mechanism can comprise a retaining member niovably disposed at least partially in the striker mass and a blocking member movably disposed hi a blocking position for blocking the retaining member from moving from the striker mass unless the predetermined acceleration event is experienced. The retaining member can be a hall disposed in a dimple on the striker mass, The blocking member can be a mass biased in t!ie blocking position by a spring member. The blocking member further can have a curved surface for accommodating a portion of the retaining member. The blocking member can be shding!y disposed relative to the base. The blocking member can be rotatably disposed relative to the base. The blocking member can he a flexural spring having a first end connected to one of the base or striker mass and a second end blocking the retaining member, and the second end can include an opening that allows the retaining member to pass when the flexural spring rotates or bends due to the predetermined acceleration event.

One or more of the base and striker mass can incl ude a pyrotechnic material which ignites upon the second projection striking the first projection.. The base can further include one or more openings for allowing a product of the ignited pyrotechnic to exit the opening.

The rotatable connection, can include a pi disposed in. at least a portion of the striker mass and base.

The rotatable connection can include a cylindrical portion on one of die striker mass and base and a corresponding cylindrical recess on the oilier of the striker mass and base.

Also provided is an inertia! igniter for igniting a thermal battery upon a predetermined acceleration event. The mertial igniter comprising: a base having two or more first projections; two or more striker masses, each rotatably connected to the base through a rotatable connection, the base having two or more second projections aligned with the two or more first projections such that when the striker mass is rotated towards the base, each of the first projections impact a corresponding one of the two or more second projections; and a rotation prevention mechanism for preventing impact of each of the first projections wife the

corresponding second projections unless the predetermined acceleration event is experienced.

Further provided is a method for igniting a thermal battery upon a predetermined acceleration event. The method comprising: rotatably connecting a striker mass to a base;

aligning a first projection on the striker mass with a second projection on the base such that when the striker mass is rotated towards the base, the first projection impacts the second projection; and. preventing impact of the first and second projections unless the predetermined acceleration event is experienced.

Still further provided is a switch for opening a circuit upon a predetermined acceleration, event. The switch comprising: a base having first and second electrical contacts configured to form a closed electrical circuit; a striker mass rotatably connected to the base through a rotatable connection, the striker mass having a member formed of an electrically insulating material, the first and second electrical contacts being aligned with the member such that when the striker mass is rotated towards the base, the member opens the circuit between the first and second electrical contacts; and a rotation prevention mechanism for preventing the member from opening the circuit unless the predetermined acceleration event is experienced.

Still further yet provided is a switch for closing a circuit upon a predetermined acceleration event. The switch comprising: a base having first and second electrical contacts configured to form an open electrical cirenit; a striker mass rotatahly connected to the base through a rotatable connection, the sinker mass having a third electrical contact formed of an electrically conductive material, the first and second electrical contacts being aligned with the third electrical contact such that when the striker mass is rotated towards the base, the third electrical contact closes the circuit between the first and second electrical contacts: and a rotation prevention mechanism for preventing the third electrical contact from closing the circuit unless die predetermined acceleration event is experienced.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the apparatus of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where;

Figure 1 illustrates a schematic of a cross-section of a thermal battery and inertia! igniter assembly of the prior art.

Figure 2 illustrates a schematic of a cross-section of a first inertia! igniter embodiment.

Figure 3 illustrates a schematic of the cross-section of the tensile-mode falhire element of a second inertia! igniter embodiment.

Figure 4 illustrates a schematic of a cross-section of another inertia! igniter embodiment.

Figure 5 illustrates a schematic of an alternative rotary joint for the inertia! igniter embodiment of Figure 4.

Fignre 6 illustrates a schematic of another alternative rotary joint for the inertia! igniter embodiment of Figure 4,

Figure 7 illustrates a schematic of a cross-section of yet another inertia! igniter embodiment.

Figure 8 illustrates a schematic of a partial cross-section of a variation of the embodiment of Figure 4,

Figure 9 illustrates a schematic of a cross-section of yet another inertia! igniter embodiment.

Figure 10 illustrates a side view of the inertia! igniter of Figure 9,

Figure 1 1 illustrates a top view of an embodiment employing multiple inertia! igniters.

Figure 12 illustrates schematic of a partial cross-section of the multiple inertial igniter embodiment of Figure 11,

Figure 13 illustrates a schematic of a cross section of a g- switch embodiment. Figure 14 illustrates a schematic of a cross section of another g-switch embodiment.

The safety related no-fire acceleration level requirements for inertial igniters that are used to initiate thermal batteries or other devices in gun-fired, munitions, mortars or the like that are subjected to high-G setback, (or impact) accelerations during the launch (or events such as target impact) are generally significantly higher than those that could occur accidentally, such as a result of the aforementioned drops .from the 7 feet heights over concrete floors. In general, the no-fire safety requirement translates to the requirement of no initiation a.t acceleration levels of around 2000 Gs with a duration of approximately 0,5 msec. However, for initiation devices that are subjected to setback acceleration levels of 10-30,000 Gs or even higher, the no -fire acceleration levels are set at well above the 2000 G levels that munitions can experience when accidentally dropped over concrete floor from, indicated heights of up to 7 feet. As a result, the no-fire acceleration, levels for such munitions are set significantly higher than those that can be experienced during accidental drops.

In. the following description and for the purpose of illustrating the methods of designing the disclosed inertial. igniter embodiments to satisfy the prescribed no-fire and all-fire requirements of each munitions, a no-fee acceleration level of 3000 G (significantly higher than the accidental acceleration levels thai may be actually experienced by the inertial igniter) and. an all-fire acceleration level of 6000 G (significantly higher than the prescribed no-fire acceleration level of 3000 G) for a duration exceeding 2 msec will be used. It is, however, noted that as long as the prescribed no- ire acceleratio level is significantly higher than those that may be actually experienced during accidental drops or the like and as long as the prescribed, all-fire acceleration level is significantly higher than the prescribed no-fire acceleration level and its duration is long enough to cause the striker mass of the inertia! igniter to gain enough energy to initiate the i gaiter pyrotechnic material, then the disclosed novel methods and various embodiments are useful to fabricate highly reliable and low cost inertia! igniters for the munitions at hand. Here, two acceleration levels are considered to have a significant difference if considering the existing range of their distributions about the indicated values, their extreme values would still be a significant amount (e.g., at least 500-1000 G) apart,

A schematic of a first embodiment 20 is shown in Figure 2. The inertia! igniter 20 is considered to be cylindrical in shape since most thermal, batteries are constructed in cylindrical shapes, but may be constructed in any other shape with the general cross-sectional view shown in Figure 2 and with its general mode of operation. The inertia! igniter 20 consists of a base element 21 (which can be separate from or integral with the thermal battery), which in a thermal battery construction shown in Figure 1 would be positioned in the housing 10 with the base element 21 positioned on the top of the thermal battery cap 1 , A striker mass 22 of the ineri!al igniter is attached to the base element 21 via a rotary⁷ joint 23. In the embodiment 20 of Figure 2, the striker mass 22 is kept separated from the base element 21 by a spring element 24 which biases the striker mass 22 away from the base element 21. , A stop element 25 is also provided to limit the counterclockwise rotation of the striker mass 22 relative to the base element 21 (the stop element opposes the biasing of the striker mass 22 due to the spring element 24). The stop element 25 is attached a post 26, which is in tarn attached to the base element .21 of the inertia! igniter 20.

The spring element 24 can be preloaded in compression sneh that with the no-fire acceleration acting on the base element 2! of the inertia! igniter in the upward direction, as shown by the arrow 27, the inertia force due to the mass of the striker mass 22 wonld not overcome (or at most be equal to) the preloading force of the spring element 24. As a result, the inertial igniter 20 is ensured to satisfy its prescribed no-fire requirement

A shearing pin 28 is also provided and is fixed to the post 26 on. one end and to a portion, such as an end of the striker mass 21 on the other end as shown in Figure 2. The shearing pin 28 is provided with a narrow neck 29, which provides for concentrated stress when the striker mass 22 is pressed down towards the base demerit 21 due to ail-fire acceleration in the direction of the arrow 27 acting on the inertia of the striker mass 22, By properly designing the geometry of the shearing pin 28 and its neck 29 and selection of the proper material for the shearing pin 28, the shearing pin 28 can be designed to fracture hi shear (and m fact in any other mode as described later in this disclosure), thereby releasing the striker mass 22 and allowing it to be accelerated in the clockwise rotation. The free end of the striker mass 22 is sized, shaped and otherwise configured so as not to interfere with any other portions, such as the post 26 when turmng about the pivot 23 upon the all-fire acceleration level. As a result for a properly designed inertial igniter 20 (i.e., by selecting a proper mass and moment of inertial for the striker mass 22, the required range of clockwise rotation for the striker mass 22 so that it would gain enough energy, considering the all-fire acceleration level and the preloading level of the spring element 24), the striker mass 22 will gain enough energy to initiate the pyrotechnic material 30 between the pinching points provided by the protrusions 31 and 32 on the base element 21 and the hottom surface of the striker mass 22, respectively, as shown in the schematic of Figure 2, The ignition flame and sparks can then travel down through the opening 33 provided in the base element 21 , When assembled in a thermal battery similar to the thermal battery 16 of Figure 1, the inertia! igniter is mounted in the housing 10 such that the opening 33 is lined up with the opening 12 into the thermal battery 11 to activate the battery hy igniting its heat pallets.

It is will be appreciated by those skilled in the art that the duration of the all-fire acceleration level is also important for the proper operation of the inertia! igniter 20 by ensuring that the all-fire acceleration level is available long enough to accelerate the striker mass 22 towards the base element 21 to gain enough energy to initiate the pyrotechnic material 30 as described above by the pinching action between the protruding elements 31 and 32.

It is will be appreciated by those skilled in the art that when the inertial igniter 20 (Figure 2) is assembled inside the housing 10 of the thermal battery assembly 16 of Figure I , a cap 18 (or a separate Internal cap - not shown) is commonly used to secure the inertial igniter 20 inside the housing 10, In such assemblies, the stop element 25 is no longer functionally necessary since the striker mass 22 is prevented hy the cap from tending to rotate in the cotmterclockwise direction by the spring element 24, thereby minimizing the shearing load on the shearing pin in the assembled thermal battery. It is, however, appreciated by those skilled in the art that by proving the stop element 25, the storage of the inertia! igniter 20 and the process of assembling it into the housing 10 is significantly simplified since one does not have to provide secondary means to keep the spring element 24 from applying shearing load to the shearing pin 28.

it will he appreciated by those skilled in the art that in place of the shearing pin 28, other types of elements that are designed to fracture upon the application of the all- firing acceleration as described above and release the striker mass 22 may he used to perform the same function. For example, the mode of fracture may be selected to be m tension, torsion or pure bending, hi general, tbe fracture can be achieved with minimal deformation in the direction that results h a significant clockwise rotation of t!ie striker mass 22 prior to pin fracture and release of the striker mass 22. This would result in minimum height requirement for the inertia! igniter since the clockwise rotation of the striker mass 22 will reduce the terminal (clockwise) rotational speed of the striker mass 22 at the instant of initiation impact between the protruding elements 31 and 32, Figure 2, and pinching of the pyrotechnic material 30 to achieve initiation.

As an example, the option of replacing the shearing pin 28, Figure 2, with a pin that Is designed to fracture In tension by when the inertia! igniter 20 is subjected to the aforementioned all-fire acceleration is show in the schematic of Figure 3. Fart of tbe base element 40, the post 41, the stop element 42 and the front portion of the striker mass 43

(indicated by numerals 21, 26, 25 and 22 in Figure 2, respectively) are shown, Tbe stop element 42 is provided with a hole and countersink 44 as shown in Figure 3, An opposite hole and countersink 45 is provided in the striker mass 43 under the stop element 42 as shows In Figure 3. A one piece tension element 46 (which can. be cylindrical in shape) with top and bottom flange portions 47 and 48, respectively, is also provided. The top flange portion 47 of the tension element 46 is assembled seating in the countersink 44 of the stop element 42 and the bottom flange portion 48 of the tension element 46 is assembled seating in the countersink 45 of the striker mass 43, The stop element 42 and tbe striker mass 43 can be provided with passages (not shown) for assembling the tension element 46 as shown in Figure 3, Alternatively, the tension element 46 may be a two part element that is assembled in place as shown in Figure 3, such as by riveting , welding or otherwise fastening the flange 47 to the stem portion of the tension element 46. The tension element 46 is also provided with, a narrow neck portion 49, which provides for concentrated stress when the striker mass 43 is pressed down towards the base element 40 du to all-lire acceleration in the direction of the arrow 27 (Figure 2) acting on the inertia of the striker mass 43, By properly designing the geometry of the tension element 46 and its neck portion 49 and selection of the proper material, the tension element 46 can be designed to fracture in tension, thereby releasing the striker mass 43 and allowing it to be accelerated in the clockwise rotation. As a result for a properly designed inertia! igniter (i.e., by selecting a proper mass and moment of inertia! for the striker mass 43, the required range of counterclockwise rotation for the striker mass 43 so that it would gain enough energy, considering the all -fire acceleration level and the preloading level of the spring element 24, the striker mass 43 will gain enough energy to initiate the pyrotechnic material 30 between the pinching points provided by the protrusions 31 and 32 on the base element 40 and tbe bottom surface of the striker mass 43, respectively, as shown in the schematics of Figures 2 and 3. The ignition flame and sparks can then travel down through the opening 33 provided in the base element 40. When assembled in a thermal battery similar to the thermal battery 16 of Figure 1 , the inertia) igniter is mounted in the housing 10 such that the opening 33 is lined up with the opening 12 into the thermal batter 11 to activate tbe battery by igniting its beat pallets.

The shearing pin can be a failure member of any configuration having a portion that is weaker than other portions about which the failure member can fail upon experiencing the all-fire acceleration level. Such weaker portion can include a material that has one or more portions having a smaller cross-sectional area than other portions and/or different materials having a weaker strength than other portions as is known in the art.

Another embodiment 50 is illustrated schematically in Figure 4. Similar to the inertia! igniter of embodiment 20 of Figures 2 and 3, the inertia! igniter 50 consists of a base element 51, which in a thermal battery construction shown in Figure 1 would be positioned in the housing 10 with the base element 51 positioned on tbe top of the thermal battery cap 1 . The striker mass 52 of the inertia! igniter 50 is attached to the base element 51 via the rotary joint 53. A post 54, which is .fixed to the base element 51 is provided with a hole 55, which in the configuration shown in Figure 4 is aligned with a dimple 56 in the striker mass 52, A ball 57 is positioned in the hole 55, extending into the dimple 56 of the striker mass 52. n the

configuration of Figure 4, the (up-down) sliding member 58 is shown to block the movement of the ball 57 out of engagement with the dimple 56 of tbe striker mass 52, thereby locking the

Π striker mass 52 m the illustrated configuration. A sliding member 58 is free to slide down against a member 60 (the rolling elements 59 are provided for illustrative purposes only to indicate a sliding joint between the sliding member 58 and the surface of the member 60). The member 60 is fixed to the base element 51, A spring element 61 resists downward motion of the sliding member 58, and is preferably preloaded in compression, so that if a downward force that is less than the compressive preload is applied to the sliding member 8, the applied force would not cause the sliding element 58 to move downwards. A stop 62, fixed to the member 60, is provided to allow the spring element 61. to be preloaded in compression by preventing the sliding member 58 from moving further up from the configuration shown in Figure 4.

During the firing, the inertia! igniter 50 is considered to be subjected to setback acceleration in the direction of the arrow 63, If a level of acceleration in the direction of the arrow 63 acts on the inertia of the sliding element 58. it would generate a downward force that tends to slide the sliding element 58 downwards (opposite to the direction of acceleration). The compression preloading of the spring element 61. is selected such that with the no-fire acceleration levels, the inertia force acting on the sliding element 58 would not overcome (or at most be equal to) the preloading force of the spring element 61. As a result, the inertia! igniter 50 is ensured to satisfy its prescribed no-fire requirement.

Now if the acceleration level in the direction of the arrow 63 is high enough, then the aforementioned inertia force acting on the sliding element 58 will overcome the preloading force of the spring element 61, and will begin to travel downward. If the acceleration level is applied over a long enough period of time (dnration) as well, i.e., if tire ail-fire condition is satisfied and the sliding element 58 will have enough time to travel down far enough to allow the ball 57 to be pushed out of the dimple 56, thereby releasing the striker mass 52 and allowing it to be accelerated in the clockwise rotation. As a result, for a properly designed inertial igniter 50 (i.e., by selecting a proper mass and moment of inertia! for tire striker mass 52 and the range of clockwise rotation for the striker mass 52 so that it would gain enough energy), the striker mass 52 will gain enough energy to initiate the pyrotechnic material 64 between the pinching points provided by the protrusions 65 and 66 on the base element 51 and the bottom surface of the striker mass 52, respectively, as shown in the schematic of Figure 4. The ignition flame and sparks can then travel down through the opening 67 provided in the base element 51. When assembled in a thermal hattery similar to tire thermal hattery 16 of Figure 1 , the inertial igmter is mounted in the housing 10 such thai the opening 67 is lined up with the opening 12 into the thermal battery 11 to activate the battery by igniting its heat pallets.

it will be appreciated by those skilled in the art that the duratio of the ail-fire acceleration level can also be important .for the operation of the inertia! igniter 50 by ensuring that the all-fire acceleration level is available long enough to accelerate the striker mass 52 towards the base element 51 to gain enough energy to initiate the pyrotechnic material 30 as described above hy the pinching action between the protruding elements 65 and 66,

It will be appreciated by those skilled in the art that when the inertia! igniter 50 (Figure 4) is assembled inside the housing 10 of the thermal battery assembly 16 of Figure I, a cap 18 (or a separate internal cap - not shown) is commonly used to secure the inertia! igniter 50 inside the housing 10. In such assemblies, the stop element 62 is no longer functionally necessary since the sliding element 58 is prevented from being pushed upward by the force of the spring element 61 and releasing the striker mass 52. It will be, however, appreciated by those skilled h the art that by providing the stop element 62, the storage of the inertia! igniter 50 and the process of assembling it into the housing 10 is significantly simplified since one does not have to provide secondary means to keep the spring element 6! from pushing the sliding element 58 farther up and passed the locking ball 57 and releasing the striker mass 52,

In the embodiment of Figure 4, the sliding and spring elements of the locking ball release mechanism may be configured in numerous ways, e.g., the sliding element 58 may be replaced with a rotating member (which may reduce the possibility of jamming) and the spring member 61 may be combined with the rotating member, i.e., as flexible beam element with the inertia of the beam acting as the mass element of the slider.

An advantage of the embodiment of Figure 4 over those of Figure 2 and 3 is that the amount of force to shear the pin or break in tension may not be reliably estimated, on the other hand, die amount and duration of acceleration to move the sliding element 58 in Figure 4 is more predictable.

The sliding element may also be provided with a cup-like base under the ball (with the bail sticking out into the sliding element and over the lip of the cup) so that a top piece is not needed to prevent the preloaded spring to push the sliding element out (up) (see e.g., U.S. Application Serial Number 12/835,709 filed on July 13, 2010, the contents of which is incorporated herein by reference). The rotary hinge 23 (53) used to attach the striker mass 22(52) to the base element 21(51) of the inertia! igniter does not have to be constructed with a pin passing through the connected rotating parts as shown in Figure 2(4), it may, for example, be constructed with a living joint. Alternatively, the joint may also be constructed with one side (for example the striker mass side) formed as a rolling surface with mating surfaces on the base element surface (Figure 5); or with an intermediate roller or balls with preloaded springs keeping them in contact (Figure 6); or other similar methods known hi the art.

Jn the rotary joint shown m Figure 5, the rotary joint is between the striker mass

71 and the base element 73. The base element 73 is provided with a preferably half-cylindrical recess 75. The striker mass 71 is provided with a matching cylindrical base 77, which allows the striker mass 1 to rotate relative to the base element 73. The spring element 78, which is attached to the striker mass 71 at point 79 on one end and to the base element 73 at point 80 on the other end, is preloaded in tension to keep the striker mass 71 and the base element 73 in continuous contact.

In the rotary joint shown in Figure 6, the rotary joint is between the striker mass

72 and the base element 74. The base element 74 is provided with a half-cylindrical recess 76. The striker mass 72 is provided with a matching cylindrical recess 81, with the roller or balls 82 disposed in the recesses 76 and 81 to form a rotary joint between the striker mass 72 and the base element 74. Similar to the rotary joint of Figure 5, a spring element 83, which is attached to the striker mass 72 at point 84 on one end and to the base element 74 at point 85 on the other end, is preloaded in tension to keep the striker mass 72 and the base element 74 in continuous contact.

It was noted that the embodiment 50 of Figure 4 requires the stop element 62 to prevent further upward motion of the sliding element 58 by the force of the eompressively loaded spring element 61. In an alternative design of this portion of the inertia! igniter 50 shown in Figure 8, the sliding element is provided with a recessed surface 100 that in the configuration of the inerti al igniter 50 shown in Figure 4 is pushed against the lower surface of the locking ball 57 as shown in the schematic of Figure 8 by the eompressively loaded spring element 61. As a result, the sliding element 58 is prevented from further upward motion.

It is appreciated by those skilled in the art that in the embodiment 50 of Figure 4 the locking bail 57 release mechanism (consisting of sliding element 58 and the spring element 61 ) could be replaced with many other types of mechanisms. One such release mechanism embodiment is shown is the schematic of Figure 7.

the embodiment of Figure 7, the components of the inertia! igniter 90 are identical to those of the embodiment 50 of Figure 4 except the locking ball 57 release mechanism components (the sliding element 58 and its related elements 59-62). which are all replaced by the components of the present embodiment, hi this embodiment 90 of the inertia! igniter, a lever element 91, attached to the hase element 51 by a rotary joint 92 is provided as shown in Figure 7. The rotary joint 92 can be t!ie same or a different rotary joint from rotary joint 53, On the free end of the lever element 91 is provided with an end 93 with the geometry that provides a surface, such as a planar surface 94 facmg the locking ball 57. In normal conditions, the lever element 91 is held, in the configuration shown in Figure 7, i.e., with the flat surface 94 facing the locking ball 57, thereby locking the striker mass 52 to the post 54 (i.e., the hase element 51), A spring element 95, which is preloaded in compression, is use to keep the lever element 91 in the configuration of Figure 7. It is noted that in this embodiment there is no need for the stop element 62 shown in Figure 4 since the compressively preloaded spring element 95 pushed the surface 94 against the surface of the post 54, thereby preventing the lever element 1 to rotate any further in the counterclockwise direction to and release the locking ball.

During the firing, the inertia! igniter 90 is considered to be subjected to setback acceleration irs the direction of the arrow 96, Acceleration in the direction of the arrow 96 will act on the inertia of the inertia of the lever element 91, and generate a downward force that would tend to rotate the lever element 91 in the clockwise direction. The compression preloading of the spring element 95 will, however, resists the clockwise rotation of the lever element 91 , The level of compressive preloading of the spring element 95 is selected such that with the no- fire acceleration levels, the inertia force acting on the lever element 1 would not overcome the preloading force of the spring element 95. As a result, the inertia! igniter 90 is ensured to satisfy its prescribed no-fire requirement,

Now if the acceleration level in the direction of the arrow 96 is high enough, then the aforementioned inertia force acting on the lever element 91 will overcome the preloading force of the spring element 95, and will begin rotate in the clockwise direction. Now if the acceleration level is applied over a long enough period of time as well, i.e., if the all-fire condition is satisfied, then the lever element 91 will have enough time to rotate enough in the clockwise direction to allow the locking ball 57 to be pushed out of the dimple 56, thereby releasing the striker mass 52 and allowing it to be accelerated in the clockwise rotation. As a result, for a properly designed inertia! igniter 90 (i.e., by selecting a proper mass and moment, of inertial for the striker mass 52 and range of clockwise rotation for the striker mass 52 so that it would gain enough energy), the striker mass 52 will gain enough energy to initiate the pyrotechnic materia! 64 between the pinching points provided by the protrusions 65 and 66 on the base element 51 and the bottom surface of the striker mass 52, respectively, as shown in the schematic of Figure 4. The ignition flame and sparks can then travel down through the opening 67 provided in the base element 51. When assembled in a thermal, battery similar to the thermal battery 16 of Figure I, the inertia! igniter is mounted in the housing 10 such that the opening 67 is lined up with the opening 12 into the thermal battery 1 1 to acti vate the battery by igniting its heat pallets.

It is appreciated by those skilled in the art that the duration of the all -tire acceleration level is also important for the proper operation of the inertial igniter 50 by ensuring that the all-fire acceleration level is available long enough to accelerate the striker mass 52 towards the base element 51 to gain enough energy to initiate the pyrotechnic material 30 as described above by the pinching actio between the protruding elements 65 and 66,

Referring now to Figure 9, there is shown anotber embodiment of an inertia! igniter, referred to generally by reference numeral 150. The inertial igniter 150 is similar to that illustrated in. Figure 7, except that link 93 (with hinge 92) and spring are replaced by a f!exur&l spring 151 , which in the embodiment of Figure 9 is fiat shaped, Tbe spring 151 is fixed to the striker element 52, such as with fasteners 1 52 or any type of fastening method known in the art. Alternatively, the spring 151 may he fixed to the base of the inertia! igniter 51. The spring 151 extends at least partly over the stiiker element 52 and bends over the front area to cover the front portion, of the release ball 57 (this portion of tbe spring 151 is indicated by numeral 154) and prevent it from moving forward and releasing the striker element 52. The spring 151 has an opening .153 as seen in the frontal view of Figure 10, as observed in the direction of fee arrow 155 of Figure 9.

When the device is subjected to acceleration in the direction of arrow 96, the acceleration acts on the inertia of the spring 151 and tend to rotate (bend) it down in the direction of the position 156, as shown with a broken line. The aforementioned portion 154 (Figures 9 and !O) will thereby move down from, the position of blocking the release hall 57, thereby allowing the ball 57 to be pushed through the opening 153 to release the striker element 52, which is then accelerated down to strike and ignite the pyrotechnic material of the menial igniter as was previously described for the embodiment of F gure 7.

In general, for the spring 151 to rotate (bend) enough to release the striker element 52, the inertia of the spring 151 must be enough to overcome its stif&ess to achieve the required amount of downward rotation (hending), However, if the inertia! of the spring 151 is not enough for a given level of acceleration in the direction of the arrow 96, the additional mass 157 (Figure 9) may be attached, to the spring 151, The size of the mass 157 and position of the mass 157 can be varied to achieve the desired spring 151 rotation (hendmg),

hi addition, the amount of acceleration in the direction of the arrow 96 that is required to allow the release ball 57 to be released should be at least equal to the specified no-fire acceleration of the inertia! igniter 150 to ensure for safety.

Referring now to Figures 11 and 12, therein, is illustrated a multiple inertia! igniter embodiment, generally referred to by reference numeral 300 in which similar elements are referred to with similar reference numerals from previous embodiments. Although the inertial igniter 90 of Figure 7 is used to describe such multiple inertial igniter embodiment, it will bs appreciated, that any of the previous embodiments described abo ve can be used, and each of the individual inertia! igniters can be the same or more than one type of inertial igniter discussed above can he employed. Further, while the inertial igniter 300 of Figures 11 and 12 is described with regard to lour inertial igniters, it will also be appreciated that any number more than one can he employed, The inertial igniter 300 is illustrated i Figure 1 .1 without a top cover 312 (which optional, but nonetheless not shown in Figure 1 ! so as to be able to view the components therein).

The inertial igniter 300 of Figures .1 1 and 12 is configured as a cylinder, but can he any shape or size. T¾e inertial igniter 300 includes a first cylinder 302 and second cylinder 304, where the first cylinder 302 has a larger diameter than the second cylinder 304. For ease of manufacturing, each of the first and second cylinders 302, 304 have a closed bottom 306, 308, respectively. However, they can share a common bottom or use a surface of the thermal battery as a bottom.

The inertial igniters 90, are distributed about a central post 310 about which the striker mass 52 and lever element 1 are pivotahiy connected (about pivots 53 and 92, respectively). The spring dement 95 is disposed in a space between the first and second cylinders 302, 304 to bias the lever element in the position shown in Figure 12. The lever element is disposed in a slot 312 formed in the second cylinder so as to be able to rotate about the pivot 92, The lever element can he biased directly against the ball 57, as shown in Figure 7, or spaced therefrom, as shown in Figure 12.

Daring the firing, the inertia! igniters 90 are considered to be subjected to setback acceleration m the direction of the arrow 96. Acceleration in the direction of the arrow 96 will act on the inertia of the inertia of the lever element 91, and generate a downward force that would tend to rotate the lever element 91 in the clockwise direction. The compression preloading of the spring element 95 will, however, resists the clockwise rotation of the lever element 91, The level of compressive preloading of the spring element 95 is selected such that with the no- fire acceleration levels, the inertia force acting on the lever element 91 would not overcome the preloading force of the spring element 95. As a result, the inertia! igniter 90 is ensured to satisfy its prescribed no-fire requirement,

Now if the acceleration level in the direction of the arrow 96 is high enough, then the aforementioned inertia force acting on the lever element 91 will overcome the preloading force of the spring element 95, and will begin rotate m the clockwise direction, Now if the acceleration level is applied over a long enough period of time as well, i.e., if the all-fire condition is satisfied, then the lever element 91 will have enough time to rotate enough in the clockwise direction to allow the locking ball 57 to be pushed out of the dimple 56, thereby releasing the striker mass 52 and allowing it to be accelerated in the clockwise rotation. As a result, for a properly designed inertia! igniter 90 (Le,_s by selecting a proper mass and moment of inertia! for the striker mass 52 and range of clockwise rotation for the striker m ss 52 so that it wonld gain enough energy), the striker mass 52 will gain enough energy to initiate the pyrotechnic material 64 between the pinching points provided by the protrusions 65 and 66 on the base element 51 and the bottom surface of the striker mass 52, respecti vely, as shown m the schematic of Figure 4, The ignition flame and sparks can then travel down through the opening 67 provided in the base element 51, When assembled in a thermal battery similar to the thermal battery 16 of Figure 1, the inertia! igniter is mounted hi the bo using 10 such that the openings 67 are lined up with corresponding openings 12 into the thermal battery 11 to activate the battery by igniting its heat pallets. The multiple inertial igniters 90 increase the reliability of the overall igniter 200 since only one has to i itiate in order to produce the required spark to ignite the thermal batter}'. Furthermore, the springs and/or striker masses can be the same for each of the inertia! igniters 90 in the multiple inertia! igniter 300 of vary between inertial igniters 90,

In the above embodiments, the disclosed devices are intended to actuate, i.e., release their striker mass (element 22 in the embodiment of Figure 2 and element 52 in the embodiments of Figures 4, 7, 9 and 12} in response to an all-fire acceleration level in the direction of the indicated arrow and accelerate downwards to impact the provided pyrotechnics materials causing them to ignite. The same mechanism used for the release of the striker mass due to an all-fee acceleration can he used to provide the means of opening or closing an electrical circui t, i.e., act as a so-called G-switch, that is actuated only if it is subjected to an all- lire acceleration profile, while staying inactive during aii no-fire conditions, even if the acceleration level is higher than the all-lire acceleration level hut significantly shorter in duration. As a result, this novel G-switch device would satisfy all no-fire (safety) requirements of the device in which it is used while activating in the prescribed all -fire condition.

A schematic of such an embodiment is shown in Figure 13. The G-switch 350 is similar to the inertial igniter illustrated is Figure 9, except thai its pyrotechnic material and initiation elements (elements 64 and 65-67 in Figure 4 and shown without the indicating numerals in Figure 9) are removed. An element 355 which Is constructed of an electrically non- conductive material is fixed to the base 51 of the device as shown hi Figure 13. The element 355 is provided with two electrically conductive elements 361 and 362 with contact ends 356 and 357, respectively. The electrical wires 358 and 359 are in turn attached to the electrically conductive elements 361 and 362, respectively. As it was described for the embodiment 150 of Figure 9, when the device is subjected to an all-fire acceleration in the direction of arrow 351, the acceleration acts on the inertia of the spring 151 and tend to rotate (bend) it down in t!ie direction of the position 156, as shown with a broken line. The portion 154 (Figures 9 and 10) will thereby move down from the position of Mocking the release ball 57, thereby allowing the hall 57 to be pushed through the opening 153 to release the element 352 (striker element 52 in Figure 9), which is then accelerated downward. The element 352 is provided with a flexible strip of electrically conductive material 353 which is fixed to the bottom surface of the element 352 (such as by being soldered or attached with fasteners 354). Therefore, as the element 352 moves do wnward towards the base 51 of the device, it would cause the flexible electrically conductive strip 353 to come into contact with the contacts 356 and 357, ther by causing the circuit through the wires 358 and 359 to close. The clement 352 can he provided with a biasing tensile spring 363 (or torsional spring positioned at its rotating joint 53, Figure 7), to ensure that the flexible electrically conductive strip 353 stays in contact with the contacts 356 and 357, It Is noted that in the schematic of Figure 13, the biasing tensile spring is show to he attached to base 51 for the sake of simplicity only, and alternatively a compressi vel.y biased spring (helical or ilexural type - not shown) may be positioned between the elements 151 and 352 to serve the same purpose.

It Is appreciated by those skilled in the art that the "normally open" (G~switch) device 350 may he readily modified to open an already closed ("normally closed") electrical circuit, or provide the means to close (open) the electrical circuit and open (close) it after the all- fire acceleratio event.

The latter goal is achieved by simply changing the biasing tensile spring 363 into a biasing compressive spring (converting the aforementioned compressively biased spring between the elements 151 and 352 into a biased tensile spring). As a result, after the a!l-fire acceleration has ended, the biasing spring would push (pull) the element 352 and thereby the flexible electrically conductive strip 353 away from the contacts 356 and 357.

The G- switch 350 of Figure 13 can also be readily modified to provide a

"normally close" switching configuration. As an example, the contact components of the G- switch 350 may be modified to that shown n the schematic of Figure 14. This embodiment 370 of the G-switch has ail its other components being the same as those of the embodiment 350 of Figure 13. The "normally closed" G-switch 370 is provided with two flexible contact elements

371 and 372, which are fixed to the electrically non-conductive member 375, which is fixed to the base 51 of the device 371. The flexible contact elements 371 and 372 are provided with contact points 373 and 374, which are normally in contact (such as by being biased towards each other), thereby causing the wires 356 and 357 that are attached to the contact elements 371 and

372 to close the electrical circuit to which they are connected to. The element 352 is provided with a non-conductive member 378 as shown in Figure 14.

As was described for the embodiment 150 of Figure 9, when die device is subjected to an all-fire acceleration in the direction of arrow 351, the element 352 (striker element 52 in Figure 9), is released and is accelerated downward. As the non -conducti e member 378 reaches the contact points 373 and 374, the force of the acceleration acting on the inertia of the element 372 causes the member 378 to be inserted between the contact points 373 and 374, thereby rendering their contacts open and opening the aforementioned electrical circuit to which the wires 376 and 377 are connected.

While there has been, shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in. form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should he constructed to cover all modifications that may fall within the scope of the appended claims.

Claims

What is claimed is:

1. An inertia! igniter for igniting a thermal battery upon a predetermined acceleration event, the inertia! igniter comprising:

a base having a first projection;

a striker mass rotatahiy connecte to the base through a rolatabie connection, the base having a second projection aligned with the first projection such that when the striker mass is rotated towards the base, the first projection impacts the second projection; and

a rotation prevention mechanism for preventing impact of the first and second projections unless the predetermined acceleration event is experienced,

2. The inertial igniter of claim \, wherein the rotation prevention mechanism comprises a restriction member for restricting rotation of the sticker mass, the restriction member being disposed directly or indirectly between the striker mass and the base.

3. The inertia! igniter of claim 2, wherein the restriction member has a weakened portion which fails upon the predetermined acceleration event thereby allowmg the striker mass to rotate towards the base.

4. The inertia! igniter of claim 2, former comprising a spring for biasing the striker mass m. a hiasing direction away from the base.

5. The mertial igniter of claim 4, further comprising a stop for limithig the movement of the striker mass in the hiasing direction.

6. The ineriial igniter of claim 3_? wherein the restriction member is arranged in shear and the weakened portion is a reduced cross-sectiona! portion,

7. The inertia) igniter of claim 3, wherein the restriction member is arranged in tension and the weakened portion is a reduced cross-sectional portion.

8. The ineriial igniter of claim L wherein the rotation prevention mechanism comprises a retaining member movably disposed at least partially in the striker mass and a blocking member movably disposed in a blocking position for blocking the retaining member from moving from the striker mass unless the predetermined acceleration event is experienced.

9. The ineriial igniter of claim 8, wherein the retaining member is a ball disposed in a dimple on the striker mass.

10. The inertia! igniter of claim 8, wherein the blocking member is a mass biased in the blocking position by a spring member.

11. The menial igniter of claim 10, wherein the blocking member further has a curved surface for accommodating a portion of the retaining member,

12. The inertia! igniter of claim 8, wherein the Mocking member is slldmgfy disposed relati ve to the base.

13. The inertial igniter of claim 8, wherein the blocking member is rotatably disposed relative to the base.

14. The inertia! igniter of claim 8, wherein the blocking member is a flexnrai spring having a first end connected to one of the base or striker mass and a second end blocking the retaining member, and the second end includes an opening that allows the retaining member to pass when the flexural spring rotates or bends due to the predetermined acceleration event,

15. The inertial igniter of claim 1. , wherein one or more of the base and striker mass includes a pyrotechnic material which ignites upon the second projection striking the first projection,

16. The inertial igniter of claim 15, wherein the base further includes one or more openings for allowing a product of the ignited pyrotechnic to exit the opening,

17. The inertia! igniter of claim 1, wherein the rotatabie connection includes a pin disposed in at least a portion of the striker mass and base.

18. The inertia! igniter of claim 1, wherein the rotatab!e connection includes a cylindrical portion on one of the striker mass and base and a corresponding cylindrical recess on the other of the striker mass and base.

1 . An inertial Igniter for Igniting a thermal battery npon a predetermined acceleration event, the inertia! Igniter comprising:

a base having two or more first projections;

two or more striker masses, each rotatably connected to the base through a rotatabie connection, the base having two or more second projections aligned with the two or more first projections such that when die striker mass Is rotated towards the base, each of the first projections impact a corresponding one of the two or more second projections; and

a rotation prevention, mechanism for preventing impact of each of t!ie first projections with the corresponding second projections unless the predetermined acceleration event is experienced.

20, A method for igniting a thermal battery upon a predetermined acceleration event, the method comprising:

rotatahly connecting a striker mass to a base;

aligning a first projection on the striker mass with a second projection on the base such that when the striker mass is rotated towards the base, the first projection impacts the second projection; and

preventing impact of the first and second projections unless the predetermined acceleration event is experienced.

21 , A switch for opening a circuit upon a predetermined acceleration event, the switch comprising:

a base having first and second electrical contacts configured to form a closed electrical circuit;

a striker mass rotatahly connected to the base through a rotatable connection, the striker mass having a member formed of an electrically insulating material, the first and second electrical contacts being aligned with the member such that when the striker mass is rotated towards the base, the member opens the circuit between the first and second electrical contacts; and

a rotation prevention mechanism for preventing the member from opening the circuit unless the predetermined acceleration event is experienced,

22, A switch for closing a circuit upon a predetermined acceleration event, the switch comprising:

a base having first and second electrical contacts configured to form an open electrical circuit;

a striker mass rotatahly connected to the base through a rotatahle connection, the striker mass having a third electrical contact formed of an electrically conductive material, the first and. second electrical contacts being aligned with, the third electrical contact such that when the striker mass is rotated towards the base, the third electrical contact closes the circuit between the first and second electrical contacts; and a rotation prevention mechanism for preventing the third electrical contact from closing the circuit unless the predetermined acceleration event is experienced.